Energy Storage Component Augments Generator Output in Heavy Equipment
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Solution Overview
Problem
Heavy equipment used in mining and construction, such as power shovels and excavators, face inefficiencies in energy management due to electrical output from generators being insufficient during peak power demands, leading to reduced performance and increased fuel consumption.
Innovation Solution
Incorporating an energy storage component, such as an ultra-capacitor, coupled with a generator and electrical bus system that supplements the electrical output during peak demands, allowing the generator to operate at a constant, optimized speed, reducing weight and fuel consumption while enhancing power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the generator is sized to meet peak power demands, then power availability is improved, but fuel consumption and engine size increase
Solution Approach 1:
The energy storage component stores energy in advance during low-demand periods when the generator operates at optimal efficiency, so that energy is available during peak-demand periods without requiring the generator to be oversized. This preliminary energy accumulation allows the generator to maintain constant optimal speed while meeting peak power needs.
2Power
If the generator operates at variable speed to meet changing power demands, then power availability is improved, but fuel consumption increases
Solution Approach 1:
The energy storage component acts as an intermediary between the generator and the power demand. It absorbs excess energy when demand is low and releases energy when demand is high, allowing the generator to operate at constant optimal speed while still meeting variable power demands. This mediator decouples the generator's operating speed from the instantaneous power requirements.
3Use of energy by moving object
If the generator operates at constant optimal speed, then fuel consumption is reduced, but power availability during peak demands decreases
Solution Approach 1:
The energy storage component stores energy in advance during low-demand periods when the generator operates at optimal efficiency, so that energy is available during peak-demand periods without requiring the generator to be oversized. This preliminary energy accumulation allows the generator to maintain constant optimal speed while meeting peak power needs.
Solution Approach 2:
The system changes the operational parameters by introducing an energy storage component that can absorb and release energy, transforming the generator's constant-speed operation into a variable-power-output system. The energy storage component's state of charge varies dynamically, enabling power availability to change while the generator speed remains constant.
4Power
If larger engines are used to meet peak power demands, then power availability is improved, but equipment weight increases
Solution Approach 1:
The energy storage component stores energy in advance during low-demand periods when the generator operates at optimal efficiency, so that energy is available during peak-demand periods without requiring the generator to be oversized. This preliminary energy accumulation allows the generator to maintain constant optimal speed while meeting peak power needs.
Solution Approach 2:
The system introduces dynamic energy storage and release capabilities, allowing the power delivery to be dynamically adjusted based on demand. The energy storage component can rapidly discharge to meet peak demands, effectively increasing available power without increasing the generator's continuous power rating or the equipment's weight.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The energy storage system effectively augments the generator's output by up to 20% during peak demands, improving the heavy equipment's performance and efficiency by reducing the need for larger engines and optimizing fuel consumption.
Implementation Method 1
an energy storage component, such as an ultra-capacitor, coupled with a generator and electrical bus system that supplements the electrical output during peak demands
Data Source
AI summary
Heavy equipment is designed for operation in a substantially-repetitive work cycle that includes lifting, rotating, and lowering steps. The heavy equipment includes a generator, an electrical bus, an energy storage component, and working components. The generator provides a substantially constant electrical output to the electrical bus, which is communicated to the working components. As such, the working components of the heavy equipment are driven directly or indirectly by the electrical output of the generator. The controller selectively couples the energy storage component to the electrical bus, and the energy storage component is configured to store electricity provided by the generator, and to provide electricity to the working components by way of the electrical bus. The electrical output of the generator is less than the power used by the heavy equipment during a portion of the work cycle, and the controller couples the energy storage component to the electrical bus to supplement the electrical output of the generator during the portion of the work cycle in which the electrical output of the generator is less than the power used by the working components of the heavy equipment.